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Alloy chain slings are widely used in heavy lifting, crane rigging, and transporting heavy goods. They play a vital role in industries such as power, manufacturing, mining, and petroleum. Known for their strength and long lifespan, alloy chain slings can last 20-30 years with proper care. However, regular inspection is crucial to maintain safety for operators and prevent equipment failure.

How Often Should Chain Slings Be Inspected?

Inspections are a key part of chain sling maintenance. There are three main types of inspections that should be performed by qualified individuals.

1. Initial Inspection

This inspection takes place when you purchase a new alloy chain sling. It involves checking the identification tags, capacity, and specifications. A link-by-link visual inspection can help identify any manufacturing defects before using the sling

2. Frequent Inspection

Frequent inspections are conducted by a competent person, typically someone with rigging experience. This inspection should take place before each job to spot any signs of wear, damage, or deformities. Some companies schedule daily checks, but inspecting before use is a safer practice.

3. Periodic Inspection

Periodic inspections are carried out by a certified inspector. The frequency of this inspection depends on how the sling is used. According to , the schedule is as follows:

• Normal use: Once a year
• Severe use: Every 3 to 12 months
• Special use: As recommended by a qualified inspector

Chain Sling Inspection Checklist

Before using a chain sling, it’s important to check for specific signs of damage. Here’s a checklist to follow:

• Missing or unreadable identification tags
• Cracks or breaks in the chain links
• Excessive wear and tear
• Nicks and gouges
• Stretched or elongated chain links or components
• Heat damage (discoloration or signs of burning)
• Rust or corrosion
• Links that don't move freely
• Weld splatter on the chain
• Damaged hooks 
• Damaged rigging hardware
• Any other visible damage that could affect safe use

If any of these issues are found, the chain sling should be removed from service immediately.

A proper inspection process includes five key steps to identify potential issues with the chain sling.

1. Twisting and Bending Chain slings are designed to handle loads with straight, end-to-end tension. If the links are bent or twisted, they’re no longer safe to use. Twisting can happen if proper padding isn’t used or if the sling is used at an improper angle. To prevent this, follow the D/d ratio, which compares the chain diameter to the object’s edge. Here’s a quick guide to how the ratio affects capacity:

2. If you notice any twisted or bent links, remove the chain from service immediately.

3. Nicks and Gouges Over time, the outer and inner parts of chain links can develop nicks and gouges from contact with loads and other surfaces. This damage can weaken the chain. Special attention should be paid to areas where stress is highest—the outside of the link body and the inner side of the straight barrels. If a nick or gouge occurs in these areas, it can compromise safety.

If the damage is shallow, it’s sometimes possible to remove it by filing it down. However, this should be done with caution, as it reduces the cross-section of the link. If a gouge is deep, the chain should be removed from service. Always refer to the manufacturer’s Wear Allowance Table to decide if the link is still usable.

4. Wear and Corrosion Wear and corrosion occur naturally over time as the chain is used. Wear happens when chain links rub against each other or drag under heavy loads. Corrosion happens when the chain is exposed to moisture, water, or chemicals. While wear can be managed with careful handling, corrosion is harder to avoid.

• Damage to the points where chain links connect
• Wear on the outer surface of the straight barrels

• Rust or rough patches on the chain’s surface
• Pitting (small holes) after cleaning and oiling

To inspect for wear, use a caliper to measure the diameter of worn areas. If the diameter is below the manufacturer’s minimum size, the chain must be removed from use. If corrosion is detected, clean and oil the chain. If pitting is visible, the chain is no longer safe to use.

5. Stretch and Chain Elongation Chain links can stretch if they are overloaded. This is one of the most dangerous types of damage because it’s not always visible. Elongation can cause chain failure during lifting. The best way to check for elongation is through a link-by-link inspection. Look for links that no longer fit together correctly or are tighter than usual.

If elongation reaches 20% of the chain’s original size, the sling must be removed from service. Check with the manufacturer’s guidelines to know the acceptable elongation limits for your chain sling.

6. Follow OSHA Guidelines the Occupational Safety and Health Administration (OSHA) has specific rules for chain sling inspection. The relevant section is 29 CFR 1910.184. Following these guidelines can help you maintain a safe workplace and avoid fines from OSHA inspectors. OSHA guidelines recommend:

• Inspecting slings regularly and keeping a record of inspections
• Make sure the chain sling is tagged with load capacity, manufacturer, and other important details
• Removing slings from service if they fail to meet inspection criteria

Conclusion

Alloy chain slings are essential for heavy lifting in demanding industries. To maintain safety and extend the lifespan of these slings, regular inspections are necessary. Follow the inspection schedules, use the checklist, and check for issues like twisting, bending, wear, corrosion, and elongation. When in doubt, remove the sling from service to avoid accidents. Adhering to ASME and OSHA guidelines will help keep your operations safe and compliant. If you need help with inspection, contact a certified rigging expert or inspector.